Frame Rust Problems of Toyota Tacoma - part 1

Frame Rust problem of the 2004 Toyota Tacoma
1

Failure Date: 02/05/2015

Tl-the contact owns a 2004 Toyota Tacoma. The contact stated the vehicle was taken to an independent mechanic for an unrelated repair and they discovered that the entire frame had rust corrosion. The vehicle had not been repaired. The manufacturer was notified of the issue. The approximate failure mileage was 56,000. Js.

Frame Rust problem of the 1998 Toyota Tacoma
2

Frame Rust problem of the 2006 Toyota Tacoma
3

Failure Date: 01/21/2015

I have a 2006 Tacoma that I bought used and it had the limited service campaign e0d (under coating) applied over the rusting frame and was told that Toyota will not replace the frame even when it rots through. This is very unsafe and Toyota should be held liable for this and forced to replace the frame.

Frame Rust problem of the 2007 Toyota Tacoma
4

Failure Date: 12/30/2014

2007 Tacoma well maintained and garage kept is showing signs of excessive rust on frame and and inside frame rails. Toyota has a campaign out at this time to cover excessive frame rust on Tacoma's in the following states. Ct DE IL in ky MA MD me mi mn nh NJ NY OH PA ri va vt WI wv, & d. C. I live in iowa which also uses salt on roads in the winter and only live 35 miles from the minnesota border, so why is my truck not covered in this salt belt campaign? I checked on line and there are many complaints of frame rust on 1996-2009 Tacoma's being deemed unsafe to drive and with frames failing after as little as 6 years.

Frame Rust problem of the 2005 Toyota Tacoma
5

Failure Date: 12/20/2014

The vehicle has significant frame rust. There are several areas on the frame where large sections of metal have delaminated. This presents a structural integrity issue in key supporting areas of the frame assembly for major components to include drive train, braking and suspension. The overall crash worthiness is in question due to the structural integrity issue presented by the frame design, metal composition and premature rusting and metal fatigue. Toyota has started a limited service campaign to apply a corrosion resistance protection, but this issue should be a safety recall. Based on the magnitude of damage from rusting in my case the only resolution would be a full frame replacement. I have pictures of the frame damage and rust available. I will also be sending Toyota a letter requesting an inspection by the regional factor representative prior to any repairs.

Frame Rust problem of the 2005 Toyota Tacoma
6

Failure Date: 12/01/2014

Toyota sent me a recall notice (that was not listed on your site) for rust on the frame. I had the dealership inspect it and they said that it is bad and Toyota will replace the frame. The dealership is telling me that specific parts (the power steering rack and lines) that are rusty will not be able to be put back when the frame is replaced (and the truck assembled again) but I have to pay the cost. I had those specific parts looked at by my mechanic and although a portion (the lines are bad and I am having replaced) the ps rack is not in bad condition. I contacted Toyota to see what they will cover and was told they will not cover parts that are not the frame. My truck is 10 years old. It is in great condition and runs great and I planned to keep it for a long time. My concern is that when you try to disassemble a whole vehicle (which is 10 years old) some of the parts that are in good working condition, once banged around trying to remove them, will break. I am concerned that I have to pay for these parts. If Toyota is replacing the frame due to safety issues, isn't it their responsibility to replace other parts that were fine prior to making the recall fix?.

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Frame Rust problem of the 2005 Toyota Tacoma
7

Failure Date: 11/26/2014

I live in ne pennsylvania and was just informed by my mechanic that my truck may not pass another inspection due to frame rust. Specifically along side the catalytic converter. My dealer said there is a limited recall in the new england states but not PA. Will Toyota expand the recall?.

Frame Rust problem of the 1997 Toyota Tacoma
8

Failure Date: 11/18/2014

Tl-the contact owns a 1997 Toyota Tacoma. The contact stated that the rear drivers and rear passengers frame is corroded, as a result the frame is rusting and chipping away in large amounts. The dealer was made aware of the failure. The manufacturer was made aware of the failure. The failure mileage was 195000. Mc.

Frame Rust problem of the 2007 Toyota Tacoma
10

Failure Date: 10/28/2014

Took Toyota Tacoma, 4x4 to team Toyota in langhorne, PA. For annual state & emissions inspections. Failed state inspection due to hole in chassis frame due to corrosive rust. Had dealer call Toyota with no results. I called from the parking lot & received a case #. Nothing else has been accomplished. Called a few days later & spoke to a corporate person. "Toyota can do nothing at this point , because a recall has not been issued for my vehicle's VIN# . My truck's chassis has been compromised & yet they won't repair it yet! this is the second time this has happened to me. The first time was a 1998 Tacoma which they bought back for the same reason--a rusted chassis frame. Think they would have corrected the problem by now! my sticker runs out at the end of November. What do I do after that? I need help to convince them to fix my truck!please!.

Frame Rust problem of the 2006 Toyota Tacoma
11

Failure Date: 10/14/2014

This is a known frame rusting problem that Toyota has not addressed properly. I took my 2006 Toyota Tacoma to the service dealer and they sprayed an anti rust compound on it. The problem is that the frame is totally rusted out and is going to be a safety issue later down the road. Toyota reached a settlement with the frame manufacturer, they did not properly coat the frame at time of manufacture. There is not a warranty on the corrosion compound after the corrosion campaign is over in March of 2016. This leaves the consumer with a truck that is not road worthy. I replaced the release bearing in my transmission, while working on it rust was literally falling in my eyes due to the amount of rust on the frame. I have never seen a frame rust out so quickly and am very disappointed that Toyota knows there is an issue but is covering it up with a thick tar like substance to "remedy" the problem. This is just covering up a down the road safety issue that should be addressed by Toyota immediately by replacing the frame. 1995 through 2000 Tacoma trucks were bought back. 2001 through 2004 received anti corrosion compound and or frame replacement. The difference is that those trucks that received the compound received a 15 year extended warranty if the frame were to fail inspection down the road. Not the case with the 2005 and up Tacomas.

Frame Rust problem of the 2006 Toyota Tacoma
12

Failure Date: 10/10/2014

I own a 2006 Toyota Tacoma prerunner, purchased new from the dealer eight years ago. In less than six years, the car’s frame started showing damages and today it shows severe rust and flaking. The severe rust under the car is widespread and in certain areas there are perforations through the frame structure. (see pictures attached). Because of this unexpected condition my Tacoma has lost considerable resale value and is resting in my driveway for fear of further damage and safety issues. (I have two small children). After some research I became aware that Toyota has acknowledged that this excessive rusting is due to a manufacturing defect and addressed the problem for some vehicle owners by either replacing the frame at no cost for the owners or buying the vehicles back. I took the car to the Toyota dealer to have it assessed and after a full inspection, the truck failed the rust frame inspection. The Toyota dealer report states as follows: “frame was found to have severe corrosion. Frame need to be replaced” with and rough estimate cost of $ 10,000. 00. I consider this defect to be a serious and unacceptable condition for a 8 year-old vehicle with Toyota’s reputation. I have invested and trusted the Toyota brand for over 20 years and feel very disappointed at how Toyota is addressing my concerns. I am asking your Toyota corporation to take my concerns seriously and to address this severe rust issue the same way you have done with 1995-2000 Tacoma owners, either by replacing my frame at no cost or buying back my vehicle.

Frame Rust problem of the 2002 Toyota Tacoma
13

Failure Date: 10/06/2014

The contact owns a 2002 Toyota Tacoma. While the vehicle was undergoing routine service, the independent mechanic discovered that a rear section of the subframe was rusted and corroded. In addition, two brackets that secured the body to the subframe detached due to rust and corrosion. The vehicle was not repaired. The manufacturer was notified. The failure mileage was 123,000.

Frame Rust problem of the 2006 Toyota Tacoma
14

Failure Date: 10/01/2014

Tl-the contact owns a 2006 Toyota Tacoma. The contact stated that the frame was corroded. The vehicle was taken to an independent mechanic. The technician verified that the frame was rusted and there was a hole in the cross member. The vehicle has not been repaired. The manufacturer was notified of the failure. The approximate failure mileage was 25,000. Pam.

Frame Rust problem of the 2004 Toyota Tacoma
15

Failure Date: 09/27/2014

I was driving down the road and noticed some unusual rattling. I stopped and upon inspection found that the frame on both sides had cracked all the way through directly above the rear tires. This rendered the vehicle extremely unsafe to drive. I had it towed to a repair shop and they told me that a complete frame replacement needs to be done and that the vehicle is unsafe to drive as is. They said the frame is completely rusted out. I understand the vehicle came out of new york and has high salt concentrations but the rest of the truck is virtually rust free. I can’t believe that a frame rusting completely out is normal in just 10 years. I have contacted Toyota (case number 1409290440) and they are telling me that any recalls pertaining to this have expired. I can’t believe they will not step up and fix what is obviously shoddy craftsmanship. My main concern is this could have caused a serious accident. They stepped up to the plate with the 1995-2000’s that had the exact same issue and obviously was not fixed in the 2001-2004 models. I am very disappointed with Toyota and very concerned for the safely of other Tacoma owners as this seems to be a pretty common issue with these trucks.

Frame Rust problem of the 2007 Toyota Tacoma
16

Failure Date: 09/19/2014

I took the truck in for it's yearly inspection and was informed that the frame will not pass inspection next year. It was suggested that I check if this truck frame was under a recall. I spoke with my Toyota dealer and was told that this truck does not fall under current criteria. I have called Toyota experience to lodge my complaint that this is unacceptable that a truck with 51335 miles frame has rusted so badly that it will not pass inspection. I am waiting for Toyota to follow up with a broadened criteria that will repair my truck frame.

Frame Rust problem of the 1998 Toyota Tacoma
17

Failure Date: 09/17/2014

This truck belongs to my son who is in the navy. He was on deployment and I took the truck to get it inspected and it failed due to a rusted frame. Neither myself nor my son were aware of the frame recall done by Toyota. I called Toyota and they are refusing to help us with this vehicle since the recall has expired. We have owned 3 Toyota Tacoma's and never have had an experience such as this. They told me to file a complaint with your company if I wasn't happy with the end result and I of course am very disappointed. My son serves this country and now he is out a vehicle and can't afford to replace it. Please advise. Thank you for your help. Daniel and sara smith.

Frame Rust problem of the 1998 Toyota Tacoma
18

Failure Date: 09/14/2014

When truck was on lift at meineke, they discovered the frame near the back wheels was rusted through so that it was unsafe to drive it. Immediately, I took it to the Toyota dealership where they confirmed that it was unsafe to drive for the same reason. There had been a recall on Toyota body frames when I had taken it to the Toyota dealership two different times in two different years and was told the body was fine. One year and 2 or 3 months after the recall was over, I am told that my truck's frame rust makes it unsafe to drive. I only have 123,595 miles on it and expected to drive it for at least 2-400,000 more. Every auto service personnel that has ever looked under the hood has told me I have kept it in very good shape. Shouldn't Toyota extend the recall in my particular case? I have all the service records from the time I bought it in 2006 when it had 64004 miles.

Frame Rust problem of the 2002 Toyota Tacoma
19

Failure Date: 08/13/2014

The contact owns a 2002 Toyota Tacoma. The contact stated that while having the vehicle inspected, the technician made him aware that the frame had completed rusted and cracked. The independent mechanic diagnosed that the frame needed to be replaced. The manufacturer was not notified of the failure. The approximate failure mileage was 168,000.

Frame Rust problem of the 2006 Toyota Tacoma
20

Failure Date: 07/21/2014

The contact owns a 2006 Toyota Tacoma. While the vehicle was undergoing an unrelated repair, the technician noticed that the entire frame was rusted. The dealer replaced the entire frame. The manufacturer was not notified of the failure. The approximate failure mileage was 93,000.

Frame Rust problem of the 2002 Toyota Tacoma
21

Failure Date: 07/18/2014

Excessive frame rust. I brought it into a Toyota dealer for an inspection for rust to the spare tire carrier. The dealer refused to perform the inspection because they said the frame was too rusty for them to safely perform the inspection.

Frame Rust problem of the 2003 Toyota Tacoma
22

Failure Date: 07/14/2014

This truck is only 11 years old and the frame is rusted out. There is a hole about 12 inches long in the frame rail, on the right side, which caused my shock mount to break in the rear of the truck. I called Toyota and they won't do anything about it. I told them I would never buy another Toyota. This frame should last longer than 11 years.

Frame Rust problem of the 1998 Toyota Tacoma
23

Failure Date: 07/07/2014

1998 Toyota Tacoma with significant frame rust. Vehicle falls within the "frame rust corrosion perforation warranty extension" program offered by Toyota. The program offers to buy back Toyota Tacomas that fail their "inspection" dealer actually dented the frame during inspection due to weak frame secondary to rust. They did not put a hole in it therefore returning it to me, saying the vehicle is safe. Contacted corporate Toyota and basically got blown off as they stated the dealer did not put a hole in it during inspection. Personally, any vehicle which you can dent the frame in critical areas with a 12 oz hammer with "light to moderate" swings is unsafe. At this point I can only hope I do not get into a crash with this vehicle. I am filing this complaint as I believe they are overlooking a potentially serious problem with the structural integrity of this vehicle.

Frame Rust problem of the 2006 Toyota Tacoma
24

Failure Date: 06/18/2014

Holes are rusting in the frame.

Frame Rust problem of the 2003 Toyota Tacoma
25

Failure Date: 06/11/2014

The contact owns a 2003 Toyota Tacoma. The contact stated that upon inspection, it was discovered that the frame was rusted. The vehicle was taken to the dealer, who confirmed that the frame had rusted. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage and the current mileage was 40,000.